Elbow clip apparatus and system

ABSTRACT

An apparatus for attenuating the transmission of an impact force from a faceguard to a helmet shell includes: at least one lobe configured to constrain at least a portion of the faceguard; a fastener attachment disk extending through recesses in the helmet shell; and a force attenuation protrusion coaxially aligned with the fastener attachment feature

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of, and claims priority to, U.S. Application Ser. No. 62/656,173, titled “A cross-functional helmet, with dynamic impact attenuating properties, which can transform from a soft helmet, without hard shell and face guard, to a hard shell helmet, with unique elbow clip fastened face guard,” filed on Apr. 11, 2018; which application is incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to protective headgear and more specifically relates to an elbow clip apparatus and related system.

BACKGROUND OF THE INVENTION

Hard shell helmets are meant to withstand high impact contact, protecting the head and face. Some hard shell helmets include a faceguard having a particular placement with respect to the helmet which is dictated by the intended use and protection desired. In many protective helmets, it is known in the relevant art to attach the faceguard to the hard shell helmet using known mechanical fastening methods including screws, rivets, clamps, or clips, or some combination thereof.

Hard shell helmets, such as those utilized to protect players of American football, are currently known in the art. Other sports and activities utilize similar protective helmets, but for the purpose of illustrating the background of the present invention, American football helmets will be discussed. These football helmets incorporate various components: a hard outer shell, inner padding, and a faceguard that is fixed to the hard outer shell, which is configured to protect the player's face while allowing for visibility and airflow. The state of the art in these types of protective helmets has changed little, if at all, in the decades since they were first introduced.

Currently, faceguards are fixedly attached to the outer shell of the helmet, therefore, an impact received to the faceguard is translated directly to the outer shell Faceguards are, by necessity, significantly rigid structures, so there is little to no attenuation of the force due to an impact, and that force is translated from the faceguard, through its fixed connection, to the helmet shell Often the full force of an impact to the faceguard translates into a large moment force directly to the head and neck of the athlete.

Player safety and increased concussion awareness has permeated through all levels of sport—from professional leagues to elementary school teams. Unfortunately, attempts in the art to improve player safety have been at the expense of player mobility, visibility, or exorbitant cost. None of which is conducive to a wide-scale implementation of a safer helmet.

There exists, therefore, an urgent need for a faceguard mounting apparatus and helmet protection system that can attenuate the impact force transferred to the wearer that is cost-effective and easy to implement. A cost-effective and easy to implement safety measure is one that is likely to be implemented and can immediately protect and benefit the players involved.

SUMMARY OF THE INVENTION

Briefly, according to one embodiment, an apparatus for attenuating the transmission of an impact force from a faceguard to a helmet shell includes: at least one lobe configured to constrain at least a portion of the faceguard; a fastener attachment disk extending through recesses in the helmet shell; and a force attenuation protrusion coaxially aligned with the fastener attachment feature. In a preferred embodiment, the apparatus may comprise a formed-metal or molded-plastic bracket portion that is configured to loop around and hold on to a portion of a faceguard. The bracket portion then is attached to the helmet shell utilizing a mechanical fastener, such as a rivet, but preferably, a screw-and-nut mated pair.

The present invention differs from the current state of the art in that the fastener attachment point of the bracket does not load the fastener directly into the helmet shell Rather, an additional component, in the form of a force attenuation disk, is present as part of the apparatus, such that any load that is experienced by the faceguard, and is translated through the bracket to the fastener, is attenuated by the disk since the disk is in between the fastener and the helmet shell.

The force attenuation disk does not behave as a rigid body, thereby absorbing some of the force, thereby resulting in a lower force being translated to the helmet shell, and therefore, to the wearer.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying figures, like reference numerals refer to identical or functionally similar elements throughout the separate views. The accompanying figures, together with the detailed description below are incorporated in and form part of the specification and serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention, in which:

FIG. 1 is an isometric view of a faceguard clip, according to an embodiment;

FIG. 2 shows a helmet assembly with faceguard clips, according to an embodiment;

FIG. 3 shows a faceguard with faceguard clips;

FIG. 4 shows a top view of a faceguard clip;

FIG. 5 shows another view of the helmet assembly of FIG. 2;

FIG. 6 shows a bottom view of a faceguard clip;

FIG. 7 shows an isometric view of the back of a faceguard clip;

FIG. 8 is an exploded view of a faceguard clip assembly;

FIG. 9 is an exploded view of an embodiment of a faceguard clip assembly where the grommet is separate from the bracket;

FIG. 10 is an exploded view of the back of the clip with the grommet;

FIG. 11 is another exploded view of the clip attachment with the grommet;

FIG. 12 shows a cross-section of an isometric view of the clip;

FIG. 13 shows the shell with recessed clip locations;

FIG. 14 shows another view of the shell with the recessed clip locations;

FIG. 15 shows a side view of the clip;

FIG. 16 shows a side view of the clip of FIG. 15 with the grommet detached;

FIG. 17 shows a partial cross-section of a helmet assembly through the center of the fastener;

FIG. 18 shows a helmet with a center-line indicating faceguard;

FIG. 19 shows how the faceguard clip angle adjusts to follow the center-line of the faceguard, according to an embodiment;

FIG. 20 shows a view of the fastener attachment disk, according to an optional embodiment;

FIG. 21 shows a T-nut lock washer, according to an embodiment;

FIG. 22 shows a view of the T-nut lock washer of FIG. 21 and a T-nut, according to an embodiment; and

FIG. 23 shows a T-nut locked in place, according to an embodiment.

While the invention as claimed can be modified into alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention.

DETAILED DESCRIPTION

We disclose a force-attenuating clip apparatus and fastening system that secures a faceguard to a helmet. A hard shell protective helmet requires a particular placement of the faceguard, depending on its desired use and other factors. The clip fastening system, as disclosed herein, easily, securely, and removably attaches a faceguard to a helmet shell, while providing additional force-attenuation above and beyond the shock-absorption provided by the shell liner and faceguard, via shock-absorbing features of the clip.

The Helmet.

A soft helmet, also known as a hard shell helmet liner, is specially designed to mitigate angular and rotational acceleration at impact for any scenario, or sport. The soft helmet is easily converted to a hard shell helmet, with hard shell and faceguard, yet still maintains all of the dynamic impact attenuation. As a hard shell, the helmet better endures more high level impacts which would also require a faceguard. The faceguard is attached to the helmet shell by clips. The clips must be positioned so as to maintain the faceguard in a position that is comfortable, safe, and does not interfere with a player's line of sight.

In one embodiment, a player wears the helmet during a heavy contact sport or activity. If the activity changes such that the player no longer requires the extra protection afforded by the hard shell, the hard shell and faceguard are removed, leaving the Liner, or soft helmet. The multi-functional helmet with clips can be advantageously used in many different sports, such as football, rugby, field hockey, and others. The helmet also has applicability for military and police use.

In one embodiment, the cross-functional helmet includes, inter alia, the following components:

1. Hard Shell and attached faceguard

2. Liner

3. Dynamic Impact Attenuating Disk (DIAD)

4. DIAD Sleeve

5. DIAD Air Bladder

6. Top Front Faceguard Bumper

7. Faceguard Elbow Clip Fastener

The impact-attenuating liner hosts the DIAD, the DIAD Sleeve, and the DIAD Air Bladder, and co-habitats within the hard shell and faceguard, which make up the entire helmet system. The DIAD Sleeve is force fit into the liner, can assist the DIAD's fixture into the liner. The DIAD air bladder system helps the overall helmet system with adjustable fit. Unique impact attenuating top front bumper that cradles the top bar of the faceguard, as well as the elbow clip fasteners which help for easy installation/disassembly of the face guard, as well as, stabilization and shock-absorption.

The DIADS are placed in the Liner thus fixed into the Liner. This acts as the liner, or soft helmet portion, of the helmet system. There is an indentation at the back bumper of the liner flap which assists in compression as the player's head is raised upward and back. There is also a special shape, or window, at the back of the hard shell that assists the flap at the Liner to move backwards. The DIAD sleeve and air bladder are components that assist the DIAD's function in fit and size adjustability. Then, the liner and DIADs are as one unit placed within the hard shell and face guard for a complete, ready to protect, high level impact football helmet. The face guard is held and secured in place by the shock absorbing top front bumper, and the uniquely designed elbow clips. The liner can be designed to assemble with the DIADs inserting from the top or bottom loading position.

In one embodiment, the hard shell is made of a composite, or injection molded plastic (ABS or polycarbonate). The DIADS are made of tpu and a proprietary closed-cell foam, or some other type of foam. The overall base form of the liner is formed with a proprietary foam. The elbow clips and top front bumper of the faceguard could be designed using materials such as, some form of plastic, tpu, surlyn, nylon, silicone, or synthetic rubber.

In one embodiment, the liner with hard shell and faceguard, as well as liner DIADS are essential for the system to operate effectively. However, in other embodiments the DIAD sleeves and DIAD air bladder can be optional. The elbow clips for the faceguard are unique in that they accommodate the angle of the faceguard wire and they attenuate the forces applied to the faceguard and transferred to the hard shell

Elbow Clips.

Although the present invention may be utilized in many different applications, the use of the invention in the context of an American football helmet is discussed herein for compactness of disclosure.

As disclosed herein, the invention may be practiced in multiple configurations in order to accommodate different types of faceguards to their respective helmet shells. Indeed, multiple configurations of the same invention disclosed herein may be utilized in a single helmet assembly, while still remaining within the scope of the invention disclosed herein.

For compactness of disclosure, and without limiting the invention, a preferred embodiment of the invention, clip 150, is discussed and shown in FIG. 1. The clip 150 is shown assembled onto a football helmet 210 in FIG. 2 where the helmet shell 100 and faceguard 240 are shown for reference only.

Referring now to FIG. 1, we show an isometric view of a preferred embodiment of the invention, namely, an apparatus for attenuating the transmission of an impact force from a faceguard 240 to a helmet shell 100 (shown in FIG. 2). In this embodiment, the apparatus is in the form of an elbow-style faceguard clip 150 with two lobes 110 configured to receive and constrain a portion of the faceguard. In this preferred embodiment, the two lobes 110 are positioned in symmetrical relation with respect to the center of the clip fastener (see FIG. 4), however, the invention contemplates the use of one lobe, two lobes, or more than two lobes. Additionally, although the preferred embodiment shows two lobes symmetrically disposed with respect to the fastener location, it is contemplated that the number, size, location, and relative angle 420 of each lobe may be configured as needed to accommodate the particular faceguard utilized. See, for example, FIGS. 18 and 19.

The clip 150 includes a special shock-absorbing ring 180 that is, preferably, substantially cylindrical, having a force attenuation protrusion central axis, with a first face disposed coplanar to the back surface, a second face disposed parallel to the first face, and having a thickness between the first face and the second face. Force attenuation protrusions are coaxially aligned with a fastener feature.

It is contemplated to be within the scope of the present invention that the ring 180 may take other forms other than cylindrical. By way of example and not limitation, the ring 180 may be octagonal in shape.

Additionally, throughout this disclosure, ring 180 may be interchangeably referred to as a grommet, pad, or disk.

The ring 180 is configured to be received within a recess integral to the hard shell 210.

In use, a force applied to the faceguard 240, a substantially rigid body, is transferred to the clip 150 at the one or more lobe 110. The lobes are made from a formed metal or strong plastic and, therefore, also react as a rigid body transferring the load to the ring 180. The ring 180 is configured to act as a shock absorber, therefore it is preferably made from force-absorbing or compressible material such as a dense foam, plastic or rubber having a durometer hardness that is less than the lobe.

In a preferred embodiment, the two lobes 110 are manufactured in an injection molding process out of a strong plastic. The ring 180 is then co-molded, or over-molded, in a second injection molding process using a softer durometer material, thereby resulting in a one-piece apparatus.

Other embodiments of the clip contemplate that the lobe portion and the ring portion be manufactured as two separate components that are subsequently joined in an assembly.

Further embodiments of the invention contemplate the inclusion of deformable areas in the ring 180, as can be seen in, for example, FIG. 6. In this way, the desired level of shock absorption may be configured through the combination of material durometer and ring geometry.

FIG. 2 shows the full helmet assembly 100, including the faceguard 240, and the clips 150 securing the faceguard 240 to the shell 210. In one embodiment, the means of attaching the clips 150 to the shell 210 includes a screw 320 and T-nut. The screw attachment is shown in FIG. 3. The order of attachment is shown in the exploded views of FIGS. 8 and 9. This embodiment, as pictured, shows the order of assembly as: outside screw 320 into elbow clip 150, then this is mated with the disk 820, then from the inside of the hard shell 210 (not shown in FIGS. 8 and 9, but is sandwiched between disk 820 and washer 830), there is a large diameter washer 830, then finally a T-Nut 840 that fastens into the washer, hard shell 210, and elbow clip 150, then, onto the outside screw 320.

The faceguard 240 needs to be in a specific area and the faceguard wire needs to be bent at specific angles in order to operate effectively. FIG. 4 is a top view of the clip 150 showing the angle 420 of the wire center-line in one embodiment. The lobes 110 of clip 150 are configured so as to accommodate the angle of the faceguard wire. The faceguard elbow clips 150 can be positioned differently to allow for varying bends and forms to accommodate faceguards of different shapes and sizes. See FIGS. 18 and 19 which show a center-line indicating the angle of a faceguard wire, according to one non-limiting embodiment. FIG. 5 shows a view of the full helmet assembly 100 with the faceguard 240 secured by the clips 150. Note that both the inside T-nut attachment 840 and the outside screw attachment 320 are shown in this figure.

FIG. 6 shows a bottom view of the clip 150 where the shock-absorbing ring 180 is shown, while FIG. 7 shows an isometric view of the back of the clip 150. An exploded view of the clip is shown in FIG. 8. FIG. 9 shows another exploded view with the grommet attachment. FIG. 10 is an exploded view of the clip 150, showing the grommet placement from the back. FIG. 11 provides another exploded view showing the grommet placement. FIG. 12 is an isometric cross-sectional view of the clip 150. FIGS. 13 and 14 both show views of the shell 210 showing the recesses where the clips are attached.

FIG. 15 is a side view of the clip 150 with the grommet in place; whereas FIG. 16 shows the clip 150 of FIG. 15 with the grommet detached. FIG. 17 is a cross-sectional view of the clip assembly attaching the faceguard 240 to the shell 210.

FIG. 20 is a view from the inside of the shell 210 showing the fastener attachment disk 820 that extends through the shell 210. In this embodiment, mating features such as protrusions 2070 on the disk 820 engage with corresponding apertures in a T-nut lock washer to couple the washer 830 to the clip 150. In an optional embodiment, the T-nut lock washer contains anti-rotation features to prevent the T-nut 840 from rotating. In this manner, the T-nut 840 can be locked to prevent the T-nut 840 from spinning while installing and removing the clip screws from the helmet shell 210. FIGS. 20, 21, 22, and 23 show one sequence of assembly illustrating how the optional T-nut lock feature is assembled to secure the clip 150 to the shell 210 while locking the T-nut 840 in place. FIG. 21 shows the T-nut lock washer 2110 disposed over the clip attachment. Apertures in the T-nut lock washer 2110 correspond to the protrusions 2070 in the fastener attachment disk 820. FIG. 22 shows how the T-nut 840 is positioned to securely mate with the T-nut lock washer 2110 of FIG. 21. FIG. 23 shows the T-nut 840 fully inserted into the T-nut lock washer 2110 of FIG. 22.

In light of the foregoing description, it should be recognized that embodiments in accordance with the present invention can be realized in numerous configurations contemplated to be within the scope and spirit of the claims. Additionally, the description above is intended by way of example only and is not intended to limit the present invention in any way, except as set forth in the claims. 

What is claimed is:
 1. An apparatus for attenuating the transmission of an impact force from a faceguard to a helmet shell, the apparatus comprising: a one or more lobe, at least partially cylindrical with a lobe central axis, configured to coaxially constrain at least a portion of the faceguard; a substantially planar area disposed adjacent to the one or more lobe having a front surface and a back surface; a fastener attachment feature that is substantially cylindrical, having a fastener attachment feature central axis, disposed perpendicular to the substantially planar area and extending through the front surface and back surface; and a force attenuation protrusion that is substantially cylindrical, having a force attenuation protrusion central axis, with a first face disposed coplanar to said back surface, a second face disposed parallel to the first face, and having a thickness between the first face and the second face, wherein the force attenuation protrusion is coaxially aligned with the fastener attachment feature.
 2. The apparatus of claim 1 where the force attenuation protrusion is made from a first material having a first durometer and the one or more lobe and the substantially planar area are made from a second material having a second durometer.
 3. The apparatus of claim 2 where the first durometer is less than the second durometer. 